Composite wall structure



June 26, 1962 P. G. SAGE 3,041,223

COMPOSITE WALL STRUCTURE I Filed May 25, 1959 FIG.I

FIG.2

INVENTOR.

Pa /z n 6212a: Y

3,041,223 Patented June 26,- 1 962 3,041,223 COMPOSITE WALL STRUCTURE Philip G. Sage, 130 W. 34th St, New York, N.Y. Filed May 25, 1959, Ser. No. 815,461 7 Claims. (Cl. 15455) This invention relates generally to cardboard structures and more .specifically to corrugated Wall structures for cartons, containers and similar packaging materials.

It is one of the primary objects of the invention to provide means facilitating interconnection of at least two layers of corrugated or groove-shaped boards, preferably consisting of cardboard, pasteboard, plastic, plastic composition and like material, to thereby obtain an extremely strong wall structure, which will withstand high pressures and bending stresses, may take up relatively heavy loads and can be manufactured at a relatively low cost.

It is another object of the invention to provide means conducive to an efiicacious wall structure of the aforesaid type, which may be readily reinforced at the central aswell as at the end or edge parts of the wall structure, and is useful for the employment in the manufacture of cartons, shipping containers and the like, for which up to now plywood and similar materials were required.

- Still another object of the present invention is to provide means rendering the possibility of obtaining strong and durable corrugated wall structures for containers of the aforesaid type, which can be readily produced on heretofore existing machines and do not require any changes in their outer appearance.

Yet another object of the present invention is to provide means envisioning a reinforced corrugated Wall structure of cardboard "and similar composite material which is very rigid, despite the fact that it is provided with recesses or cutouts, but which will not contribute to any reduction in strength of the final product, which is highly resistant to stresses exerted in various directions.

It is a still further object of the present invention to provide means devising a reinforced corrugated wall structure of the aforesaid type, which may be arranged with its corrugations in such a manner as to fulfill all practical requirements at locations'thereof where the greatest pressure or-stress occurs. 7

These and other objects of the invention will become further apparent from the following detailed description, reference being made to the accompanying drawing showing a preferred embodiment of the invention.

In the drawing: 1 7

FIG. 1 is a fragmentary-perspective view of a corrugated wallstructure with a reinforcing element thereof in the process of being inserted into said structure embodying the invention;

FIG. 2 is an end elevational view of the corrugated structure of FIG. 1 in assembled condition; and

FIG. 3 is a view similar to that of FIG. 1, but showing the invention in somewhat modified form and with the reinforcing element forming an integral part of the structure.

FIG. 4 is a perspective View, partly shown in section of modified corrugated wall employa-ble in the invention.

Referring now more particularly to the drawing, there is shown a wall structure consisting of a lower corrugated member 11 and an upper corrugated member 12, both made of cardboard or similar composite material. Each member 11, 12 is fluted at 13 and 14 respectively and has a crest 15 and 16.

As can be more clearly seen in FIGS. 1 and 2, the lower corrugated member 11 is provided with a series of cut outs 17 into which substantially snugly fit the lowermost crests or bottom edges 18 of corrugated member 12, whereby the cut outs 17 are substantially completely filled by said lowermost crests or bottom edges 18. It will be observed that the normal distance between the uppermost crests 16 of member 12 and the uppermost crests 15 of member 11 when in superposed position is only inappreciably or slightly changed, when the lowermost crests 18 engage the cutouts 17 of member 11, as apparent from FIG. 2.

Toward the ends of corrugated member 11 and in particular at locations thereof where great stress or pressure p is exerted, there are provided adjacent recesses or perforations 20 which are spaced from each other at a lesser distance than the cut outs 17.

While the successive lowermost edges 18 of the corrugated member 12 fit into respective cut outs 17 in substantially equal spaced apart relation, the recesses 20 are used for inserting slab-like elements or reinforcing strips 19, which on the one hand at their bottom edges 21 are held and retained in the respective recesses 20 and on the other hand abut at their upper edges 22 against the inner upper surface edges 16a of the corrugations of member 12.

Above the crests 16 of corrugated member 12 and in abutment with the crests 16 there extends a flat paper or cover sheet 23 to hold down corrugated member 12 onto lower corrugated member 11, as it may be well understood.

The outermost ends 24 of this sheet 23 are bonded to the lowermost corrugated member 11 as at 24, whereby a sturdy corrugated composite wall structure 10 is obtained, which prevents any shifting of the corrugated members 11, 12 with respect to each other.

The aforesaid structure includes further the provision of means, such as elements 19 to reinforce the corrugated Wall structure 10 at any location or locations thereof, as desired.

FIG. 3 shows a further embodiment of the invention in the form of a composite corrugated wall structure 30 having the lower corrugated member 31 and the upperv corrugated member 32.

In this particular instance the lower corrugated member 31 is provided with cut outs 33 for adjusting and nesting therein the lower crests or edges 34 of the corrugated top member 32.

As can be seen from FIG. 3, the regularly spaced apart corrugation sections 35 may be changed in their formations as seen at 36, whereby two successive corrugations 35 are placed directly adjacent each other as indicated at 34a, which together fit into respective recesses 33 extending across the crests 37 of the lower corrugated member 31.

The lower corrugated member 31 may be also transformed, preferably at their respective lateral ends as at 38 to correspond in shape and dimensions to thereinforcements indicated at 36 of the upper corrugated member 32. In contradistinction to the wall structure seen in FIGS. 1 and 2, the separate reinforcement elements or slabs 19 of FIG. 1 are thus replaced by integral reinforcements 34a, 38.

It is well'understood that the reinforcing slabs or struts whether integral with the corrugated wall or walls or not may be arranged in any desired angle to each other and do not have to extend necessarily normal to the corresponding crests of the corrugated wall or walls or parallel to each other.

Referring now more particularly to FIG. 4, there is disclosed a corrugated base wall structure 40 having corrug-ations 41 the crests 42 thereof being provided with slits 43 arranged in predetermined spaced relation to each other. These slits or scored lines may penetrate to a certain extent in a downward direction the corresponding crests of the corrugations 41 and greatly simplify the product without weakening the structure when an upper corrugated member, such as 12 or 32 is to be assembled in a manner as hereinabove set forth.

In some instances it appears to be preferable that the lower corrugated member 40 be made of sufficient elastic material to facilitate easy assembly of the composite corrugated wall structure. It is well understood that slits 43 readily open up and provide the necessary grooves or recesses :for the upper corrugated member, whose corrugations will fixedly engage with the respective opened slits of the lower corrugated member without materially reducing the strength of the then assembled corrugated wall structure.

It is further to: be stressed that the lower corrugated member 40 (FIG. 4) may be made of a different material than that of the upper corrugated member and may have greater elasticity than the latter. In the particular instance shown in FIG. 4 corrugated member 40 may be made from a rubberized or plastic material, whose slits may be readily spread or opened up for frictionally engaging corresponding corrugations of an upper corrugated member (not shown).

It can thus be seen that there has been provided in accordance with the present invention a composite corrugated wall comprising a plurality of corrugated elements arranged in superposed position and extending in crosswise directions to each other, one of said elements located below an adjacent upper element being provided with a plurality of cut outs having a predetermined dis tance from each other and positioned in the crests of the corrugations of said one element, whereby the corrugations of said upper element may be seated in said cut outs and fixedly engaged with said one element, said one element being provided with perforations provided only in some of the crests of its corrugations, said perforations being located approximately midway between two adjacent cut outs, and means disposed between said upper corrugated element and said one corrugated element and extending from said perforations of said one element for contact with the underfaces of the crests of the corrugations of said upper element.

Various changes and modifications may be made without departing from the spirit and scope of the present invention and it is intended that such obvious changes and modifications be embraced by the annexed claims.

Having thus described the invention, what is claimed as new and desired to be secured by Letters Patent is:

1. A composite wall structure for use in connection with the manufacture of containers comprising at least two corrugated walls arranged in superposed relation to each other, the upper crests of one of said corrugated walls extending in transverse direction to the upper crests of the other of said corrugated walls, the lower corrugated wall being provided with shallow cut outs located a predetermined distance from each other in the upper crests of the corrugations of said lower wall, so that the upper corrugated wall nested with its corresponding lower corrugations in said cut outs, said lower corrugated wall being further provided with recesses located between adjacent cut outs, reinforcing means extending from said uppercorrugated wall to said lower corrugated wall and in engagement with said recesses, to thereby prop predetermined corrugations of said upper corrugated wall relative to said lower corrugated wall, and means overlying said corrugated walls in said superposed relation and in cont-act with crests of the uppermost corrugated wall and bonded to the lowermost corrugated wall.

2. A composite wall structure according to claim 1, said reinforcing means forming separate struts extending from said recesses to the corresponding underfaces of said upper crests of said upper corrugated wall.

3. A composite wall structure according to claim 1, said reinforcing means being formed by two adjacent corrugations of and integral with said upper corrugated wall and by two adjacent corrugations of and integral with said lower corrugated wall.

4. A composite wall structure according to claim 1, said overlying means forming cover sheet means extending over and bonded to the crests of said upper corrugated wall and fastened to a crest of said lower corrugated wall.

5. A composite corrugated wall comprising at least two corrugated elements in superposed position and extending in crosswise directions to each other, the lower corrugated element being provided with a plurality of cut outs having a predetermined distance from each other and positioned in at least some of the crests of the corrugations of the lower element, so that the upper element is seated with its corresponding corrugations in said cut outs and is fixedly engaged with said lower element, said lower element being provided with perforations in the crests of its corrugations, said perforations being located approximately midway between two adjacent cut outs, and prop means disposed between said upper corrugated element and said lower corrugated element and extending from said perforations of said lower element to the underfaces of the crests of the corrugations of said upper element.

6. A composite corrugated wall comprising a plurality of corrugated elements arranged in superposed position and extending in crosswise directions to each other, one of said elements located below an adjacent upper element being provided with a plurality of cut outs having a predetermined distance from each other and positioned in the crests of the corrugations of said one element, so that the corrugations of said upper element are seated in said cut outs and fixedly engaged with said one element, said. one element being provided with perforations provided only in some of the crests of its corrugations, said perforations being located approximately midway between two adjacent cutouts, means disposed between said upper corrugated element and said one corrugated element and extending from said perforations of one element for contact with the underfaces of the crests of the corrugations of said upper element, and means extending from said upper element to said one element and bonded to the latter, the normal distance between the uppermost crests of said upper element and the uppermost crests of said one element being slightly reduced, when said upper element is engaged in the cut outs of said one element.

7. A wall according to claim 6, said one element being made of a material relatively yieldable with respect to the material of said upper element.

References Cited in the file of this patent UNITED STATES PATENTS 1,875,188 Williams Aug. 30, 1932 1,996,490 Romanofi Apr. 2, 1935 2,224,810 Cumfer Dec. 10, 1940 2,746,892 Elfving May 22, 1956 2,833,682 De Laszlo May 6, 1958 

6. A COMPOSITE CORRUGATED WALL COMPRISING A PLURALITY OF CORRUGATED ELEMENTS ARRANGED IN SUPERPOSED POSITION AND EXTENDING IN CROSSWISE DIRECTIONS TO EACH OTHER, ONE OF SAID ELEMENTS LOCATED BELOW AN ADJACENT UPPER ELEMENT BEING PROVIDED WITH A PLURALITY OF CUT OUTS HAVING A PREDETERMINED DISTANCE FROM EACH OTHER AND POSITIONED IN THE CRESTS OF THE CORRUGATIONS OF SAID ONE ELEMENT, SO THAT THE CORRUGATIONS OF SAID UPPER ELEMENT ARE SEATED IN SAID CUT OUTS AND FIXEDLY ENGAGED WITH SAID ONE ELEMENT, SAID ONE ELEMENT BEING PROVIDED WITH PERFORATIONS PROVIDED ONLY IN SOME OF THE CRESTS OF ITS CORRUGATIONS, SAID PERFORATIONS BEING LOCATED APPROXIMATELY MIDWAY BETWEEN TWO ADJACENT CUT OUTS, MEANS DISPOSED BETWEEN SAID UPPER CORRUGATED ELEMENT AND SAID ONE CORRUGATED ELEMENT AND EXTENDING FROM SAID PERFORATIONS OF ONE ELEMENT FOR CONTACT WITH THE UNDERFACES OF THE CRESTS OF THE CORRUGATIONS OF SAID UPPER ELEMENT, AND MEANS EXTENDING FROM SAID UPPER ELEMENT TO SAID ONE ELEMENT AND BONDED TO THE LATTER, THE NORMAL DISTANCE BETWEEN THE UPPERMOST CRESTS OF SAID UPPER ELEMENT AND THE UPPERMOST CRESTS OF SAID ONE ELEMENT BEING SLIGHTLY REDUCED, WHEN SAID UPPER ELEMENT IS ENGAGED IN THE CUT OUTS OF SAID ONE ELEMENT. 